US20190357627A1 - Footwear insert formed from a composite assembly having anti-puncture and anisotropic properties - Google Patents
Footwear insert formed from a composite assembly having anti-puncture and anisotropic properties Download PDFInfo
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- US20190357627A1 US20190357627A1 US15/987,858 US201815987858A US2019357627A1 US 20190357627 A1 US20190357627 A1 US 20190357627A1 US 201815987858 A US201815987858 A US 201815987858A US 2019357627 A1 US2019357627 A1 US 2019357627A1
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B7/00—Footwear with health or hygienic arrangements
- A43B7/32—Footwear with health or hygienic arrangements with shock-absorbing means
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/026—Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/04—Plastics, rubber or vulcanised fibre
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/12—Soles with several layers of different materials
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- A—HUMAN NECESSITIES
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- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
- A43B13/141—Soles; Sole-and-heel integral units characterised by the constructive form with a part of the sole being flexible, e.g. permitting articulation or torsion
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- A—HUMAN NECESSITIES
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- A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
- A43B13/16—Pieced soles
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- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
- A43B17/003—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material
- A43B17/006—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material multilayered
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
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- D—TEXTILES; PAPER
- D03—WEAVING
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- D03D1/0041—Cut or abrasion resistant
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- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
- D03D15/267—Glass
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B5/00—Footwear for sporting purposes
- A43B5/002—Mountain boots or shoes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
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- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
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- D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
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- D10B2501/00—Wearing apparel
- D10B2501/04—Outerwear; Protective garments
- D10B2501/043—Footwear
Definitions
- This application relates in general to footwear inserts used in sole assemblies for articles of footwear and, in particular, to footwear inserts having anti-puncture and anisotropic bending properties.
- materials are isotropic or anisotropic.
- Isotropic materials have identical properties in all directions. Conversely, properties of anisotropic materials are directionally and geometrically dependent.
- footwear products incorporate materials that provide a selected degree of stiffness while still allowing for some flexibility for bending during use. Oftentimes, however, desired characteristics within a shoe can be at odds with other desired characteristics. For example, footwear products having sole assemblies that incorporate isotropic materials configured to provide enhanced flexibility and range of motion for the wearer's foot often sacrifice structural stiffness and/or stability. Conversely, the use of isotropic materials to provide enhanced structural stiffness and stability are often at the sacrifice of flexibility.
- footwear products also incorporate materials that provide protection and security to a wearer's foot.
- the sole assemblies of footwear products are often designed to protect the bottom of a wearer's foot from rough and uneven terrain.
- most sole assemblies are typically formed from a relatively soft material (e.g., rubber) that offers little puncture protection from sharp objects, such as nails, screws, wires, spikes, etc.
- footwear products configured to offer improved puncture resistance often include sole assemblies having puncture resistant layers formed from very stiff and rigid materials (e.g., metal, rigid plastic, etc.) or very flexible materials (e.g., fabric such as Kevlar®).
- footwear products that incorporate puncture resistant layers formed from very stiff and rigid materials limit the flexibility of the footwear product, thereby reducing the wearer's comfort
- footwear products that incorporate puncture resistant layers formed from very flexible materials offer limited stiffness and stability, resulting in a reduced ability to distribute point loads over larger portions of the sole assembly. Accordingly, there is a need for a footwear insert that can be used as a puncture resistant layer while providing sufficient flexibility to the wearer's foot motion without limiting the stiffness, stability, and load distribution of the footwear product under foot.
- FIG. 1 is an isometric view of a footwear insert formed from a fiber-based composite assembly having anti-puncture and anisotropic properties configured in accordance with embodiments of the present technology.
- FIG. 2 is a side elevation view of a footwear assembly.
- FIG. 3 is an exploded isometric view of the composite assembly forming the insert of FIG. 1 .
- FIG. 4 is an isometric view of the composite assembly of FIG. 3 shown in a planar, un-flexed configuration in accordance with embodiments of the present technology.
- FIG. 5 is an enlarged cross-sectional view taken substantially along line 5 - 5 of FIG. 4 showing the top and bottom layers of the composite assembly configured in accordance with an embodiment of the present technology.
- FIG. 6 is a schematic side elevation view of the insert of FIG. 1 shown in an upward deflection configuration (broken lines), neutral configuration (solid lines), and a downward deflection configuration (broken lines).
- FIGS. 7A-C are schematic cross-sectional views of the footwear assembly of FIG. 2 having the footwear insert of FIG. 1 in accordance with an embodiment of the present technology.
- FIG. 8 is a schematic flow chart regarding a method of manufacturing the footwear insert of FIG. 1 in accordance with an embodiment of the present technology.
- FIG. 1 depicts a footwear insert 10 having puncture-resistant and anisotropic bending properties.
- the insert 10 is shown in a planar, un-flexed configuration.
- the footwear insert 10 is formed from a composite assembly 12 that comprises a soft layer 14 formed from a woven, fiber reinforced material and a hard layer 16 formed from a fiber reinforced composite material and fixedly and permanently joined with the soft layer 14 .
- the footwear insert 10 has a generally foot-shaped layout that includes a heel portion 18 and an opposing forefoot portion 20 , where the heel portion 18 is configured to be positioned beneath a wearer's heel, and the forefoot portion 20 is configured to be positioned beneath a wearer's forefoot when the footwear insert 10 is incorporated into a footwear assembly 22 ( FIG. 2 ).
- the footwear insert 10 has a longitudinal axis 24 extending substantially through both the heel portion 18 and the forefoot portion 20 and a lateral axis 26 substantially perpendicular to the longitudinal axis 24 .
- the composite assembly 12 forming the insert 10 is a bendable planar assembly which is described herein with reference to the spatial orientation shown in FIG. 1 . Accordingly, the soft layer 14 is shown in FIG. 1 as a top layer and the hard layer 16 is shown as a bottom layer. It is noted that the terms “top” and “bottom” are used for purposes of convenience to discuss orientation, and it is to be understood that the assembly can be positioned in other spatial orientations, such as an inverted orientation to that shown in FIG. 1 , so that the first layer 14 is below the hard layer 16 .
- the upper 28 is fixedly attached along the bottom margin to a sole assembly 30 , which includes an outsole 32 and a midsole 34 , where the midsole is fixedly coupled to the outsole 32 and configured to be positioned between the upper 28 and the outsole 32 .
- the footwear assembly 22 may incorporate the footwear insert 10 ( FIG. 1 ) into the sole assembly 30 .
- the incorporated insert 10 may be coupled to the midsole 34 and may be sized and shaped such that it extends fully underfoot from a forefoot portion 36 , through an arch portion 38 , to a heel portion 40 of the footwear assembly 22 .
- a running shoe may increase flexibility and cushioning at the sacrifice of stability and protection.
- the increased flexibility is commonly achieved through outsole and midsole design that provides segments in the sole in flexing regions of the shoe. While this does increase flexibility, the torsional stiffness can be considerably reduced, and the plantar flex protection can be substantively sacrificed.
- a hiking boot that often sacrifices flexibility for increased protection and stability. The use of rigid materials in the construction of the sole of the hiking boot increases the stiffness so as to distribute loads and reduce transmission of point loads to the wearer's foot, thereby preventing, for example, foot bruising from rocks or roots on a hiking trail.
- the tensile and compressive properties of both the joined soft layer 14 and the hard layer 16 cause the footwear insert 10 to have desirable anisotropic bending properties in which the footwear insert 10 has a high resistance to bending in a first direction (e.g., with the toe and/or heel portions flexing downwardly), and a low resistance to bending in an opposing second direction (e.g., with the toe and/or heel flexing upwardly). Because of these desirable bending properties, the footwear insert 10 provides stability and comfort to the wearer of the footwear assembly 22 by restricting bending of the sole assembly 30 in a plantar flex direction without adversely affecting bending in a dorsal flex direction.
- FIG. 3 depicts an exploded view of the composite assembly 12 .
- the soft layer 14 comprises a woven material formed from multiple layers of fabric stacked and coupled together and configured to act as a puncture resistant layer that resists and/or prevents penetration by sharp objects such as nails, screws, and the like.
- the layers of fabric are each formed from fiber bundles densely woven together into a fine mesh having warp fiber bundles woven with weft fiber bundles, where the warp fiber bundles are substantially parallel to each other and the weft fiber bundles are substantially parallel to each other.
- the fiber bundles are formed from a non-rigid fibrous material.
- the fiber bundles are formed from polyester fibers and the woven material is a polyester material.
- the non-rigid fabric is formed from Kevlar, Dyneema (i.e., ultra-high molecular weight polyethylene), or some other flexible woven fabric.
- the individual layers of fabric are stacked together and mechanically bonded (e.g., stitched, needled, etc.) to each other in a multi-layer arrangement.
- the soft layer 14 may have a thickness in the range of between approximately 2.0 mm-5.0 mm. In one embodiment, the soft layer 14 has a thickness of approximately 4 mm.
- the soft layer 14 may also include a bonding agent (i.e., a binder or adhesive) applied to the fabric layers so as to further bind the individual layers to each other.
- a bonding agent i.e., a binder or adhesive
- the soft layer 14 in other embodiments can be a puncture resistant layer made of other anti-puncture fabric weaves that can have multiple layers of dense fibers bonded, stitched, or pressed together.
- the fibers in the fabric of the illustrated embodiment may be woven such that the warp and weft fiber bundles are oriented at a selected angle relative to each other and/or relative to the longitudinal axis 24 and the lateral axis 26 .
- the warp and weft fiber bundles are woven at approximately a 90-degree orientation relative to each other.
- each of the layers of fabric may have a common orientation with respect to the longitudinal and lateral axes 24 and 26 .
- each of the layers of fabric may be oriented such that the warp fiber bundles are substantially parallel to the longitudinal axis 24 . In other embodiments, however, each of the layers of fabric may not be oriented in a common orientation.
- a first of the layers of fabric may be oriented such that its warp fiber bundles are parallel to the longitudinal axis 24 while a second of the layers of fabric is oriented such that its warp fiber bundles are oriented at an angle of approximately 30-degrees with respect to the longitudinal axis 24 .
- the hard layer 16 comprises a fiber-reinforced composite material. More specifically, the hard layer 16 comprises a rigid epoxy plate having one or more layers of fibers woven together and impregnated with an epoxy.
- the fibers comprise synthetic fibers, such as fiberglass fibers, and the epoxy comprises a cured thermoset epoxy.
- the synthetic fibers comprise carbon fibers or some other type of fiber, and the epoxy comprises thermoplastic polyurethanes, thermoplastic elastomers, thermoplastic polyolefins, silicone, acrylates, polyamides, polyurethanes, nitrile and butyl rubbers, and styrenic block copolymers.
- the composite assembly 12 acts as a puncture resistant assembly capable of preventing or inhibiting penetration of a foreign objection.
- the rigid epoxy plate of the hard layer 16 provides impact resistance and maintains overall stiffness of plate when impacted by an object. If the object is able to penetrate through the hard layer 16 , however, the soft layer 14 adds further puncture resistance.
- the bonded and overlapping fabric layers of the soft layer 14 are flexible enough to absorb the penetrating objects force and prevent penetration.
- the object when a wearer steps on an object that could puncture a conventional sole assembly, the object applies a point load on a portion of the insert 10 , which causes a portion of the insert 10 at the load point to flex in the plantar flex direction, which puts the fibers in the soft layer in tension, thereby tightening the fibers together, which further resists and prohibits penetration of the object through the insert to the wearer's foot.
- the woven fabric merely bends and deforms without breaking and the stacked layers compress into each other without breaking.
- the hard layer 16 includes the woven reinforcing fibers impregnated with uncured epoxy.
- the soft layer 14 is positioned on top of the hard layer 16 and the composite assembly 12 is exposed to heat and pressure (e.g., via a heat press) in order to cure the epoxy and bond the two layers 14 and 16 together.
- heat and pressure e.g., via a heat press
- the uncured epoxy of the hard layer 16 diffuses partially into the soft layer 14 and impregnates or otherwise adheres to at least some of the woven fabric of the soft layer 14 .
- the uncured epoxy may diffuse across the entirety of the soft layer 14 and impregnate at least most of the woven fabric before curing and hardening.
- the cured epoxy may be too dispersed throughout both of the layers 14 and 16 to provide the desired amount of rigidity to the hard layer 16 , resulting in the composite assembly 12 being too rigid and the footwear insert 10 not having the desired bending properties.
- the composite assembly 12 may be formed by curing the epoxy of the hard layer 16 as an initial process, then in a secondary process position the soft layer 14 on the hard layer 16 and apply sufficient heat and pressure so as to fixedly bond the soft layer 14 to the hard layer 16 .
- the composite assembly 12 of the illustrated embodiment also includes at least one interfacing layer 42 positioned between the soft layer 14 and the hard layer 16 .
- the interfacing layer 42 is formed from one or more thin sheets of polymer and is configured to act as an adhesive that bonds the soft layer 14 to the hard layer 16 while simultaneously preventing the unrestricted flow of uncured epoxy.
- the interfacing layers 42 are elastomeric bonding layers formed from sheets of a block copolymer, such as a polyether block amide (e.g., PEBAX 2533), having a thickness in the range of approximately 0.004-0.012 inches (0.1 mm-0.3 mm), and more preferably a thickness of approximately 0.008 inches (0.2 mm) and having polymer chains arranged in a network.
- a block copolymer such as a polyether block amide (e.g., PEBAX 2533)
- PEBAX 2533 polyether block amide
- the thermal energy and pressure used to cure the epoxy in the hard layer 16 also causes the polymer chains to begin to flow and move around, becoming partially embedded within the soft and hard layers 14 and 16 .
- the heat and pressure causes cross-linking between adjacent polymer chains that prevents/limits further movement of the polymer chains, causing the polymer to harden and cure.
- the soft layer 14 , the hard layer 16 , and the interfacing layer 42 are co-cured together to form the composite assembly 12 .
- the polymer chains which now span between the woven fabric and the composite material, permanently bind the two layers together.
- the cross-linked polymer chains also act as a semipermeable barrier that limits the flow of the epoxy material into the soft layer 14 from the hard layer 16 during the curing process.
- the uncured epoxy may be able to flow through the interfacing layer 42 , the majority of the epoxy material is not, thereby ensuring that most of the epoxy remains within the hard layer 16 and that the hard layer 16 has a sufficient stiffness and rigidity, which is greater than that of the soft layer 14 , after the curing process is completed.
- FIG. 4 shows an isometric view of a segment of the composite assembly 12 having opposing ends 48 and arranged in a planar and relaxed position (i.e., a neutral orientation), and FIG. 5 shows a cross-sectional view of the composite assembly 12 taken along line 5 - 5 of FIG. 3 .
- the assembly 12 has a neutral bending plane 44 near the bottom of the soft layer 14 and substantially parallel to the interfacing layer 42 .
- the neutral bending plane represents the theoretical plane that separates the portions of the object in tension from the portions in compression when the object is bent. For example, when bending the composite assembly 12 , portions of the composite assembly 12 on one side of the neutral bending plane 44 are in tension, while the portions on the opposing side are in compression.
- bending the composite assembly 12 about the lateral axis 24 such that the opposing ends 48 move in a generally upward direction causes the portions of the composite assembly 12 above the neutral bending plane 44 to be in compression and the portions below the neutral bending plane 44 to be in tension.
- bending the composite assembly 12 such that the opposing ends 48 move in a generally downward direction causes the portions of the composite assembly 12 above the neutral bending plane 44 to be tension and the portions below the neutral bending plane 44 to be in compression.
- the bending properties (e.g., the resistance to bending in a given direction) of the composite assembly 12 are dependent on the tensile and compressive properties of the different portions of the composite assembly 12 . More specifically, the bending properties of the composite assembly 12 are dependent on the tensile and compressive properties of both the woven material of the soft layer 14 and the fiber-reinforced composite material of the hard layer 16 .
- FIG. 6 depicts the composite assembly 12 in an upward deflection configuration, a neutral configuration, and a downward deflection configuration.
- all of the material above the neutral bending plane 44 i.e., a majority of the woven fabric of the soft layer 14
- all of the material below the neutral bending plane 44 i.e., the rest of the woven fabric of the soft layer 14 and all of the hard layer 16
- the opposing ends 48 of the composite assembly 12 have an upward deflection 50 .
- the composite assembly 12 is forced into the downward deflection configuration
- the material above the neutral bending plane 44 is in tension while the material below the neutral bending plane is in compression and the opposing ends 48 have a downward deflection 52 .
- the differences between the tensile and flexural properties of the joined soft and hard layers 14 and 16 are such that the composite assembly 12 has anisotropic bending properties. Accordingly, when the composite assembly 12 is bent via a force or load (i.e., a flexural load), if the flexural load causes an upward deflection, the extent of upward deflection 50 will be greater (i.e., the composite assembly will bend more) as compared to the extent of downward deflection 52 that will occur in response to the same flexural load applied in the opposite direction.
- the soft layer 14 has a tensile modulus and a flexural modulus smaller than the tensile modulus and flexural modulus of the hard layer 16 .
- the soft layer 14 has a tensile modulus in the range of approximately 0.5 GPa to 15 GPa and the flexural modulus is in the range of approximately 0.01 GPa to 5 GPa.
- the hard layer 16 has a tensile modulus in the range of approximately 5 GPa to 250 GPa and the flexural modulus is in the range of approximately 1 GPa to 100 GPa.
- the tensile and flexural modulus of the hard layer are greater than the tensile and flexural modulus of the soft layer.
- the ratio of the tensile modulus of the soft layer 14 vs. the hard layer 16 is in the range of approximately 1:1.5 to 1:25.
- the soft layer 14 has a tensile modulus of approximately 5 GPa and a thickness in the range of approximately 1.5 mm-5 mm
- the hard layer has a tensile modulus of approximately 30 GPa and a thickness in the range of approximately 0.1 mm-0.25 mm.
- one embodiment of the composite assembly 12 has the soft layer 14 made of woven polyester/Kevlar/Dyneema with a thickness of approximately 4.0 mm, a tensile modulus of approximately 7 GPa.
- the hard layer 16 is made of Fiberglass/Epoxy Pre Preg. with a thickness of approximately 0.2 mm, a tensile modulus of approximately 30 GPa.
- the resulting assembly 12 has a thickness of approximately 4.5 mm.
- the fabric of the soft layer 14 When the composite assembly 12 is subjected to a load causing bending in the downward deflection direction 52 , the fabric of the soft layer 14 is put in tension. As the soft layer 14 has a higher tensile modulus than its own flexural modulus, it resists the deflection of the composite assembly 12 in the downward flex direction. However, when the bending is in the opposite, upward flex direction, the fabric of the soft layer 14 is under compression. The soft layer 14 has very low rigidity and compressive/flexural modulus in comparison to the hard layer, and the fibers of the soft layer 14 are not encapsulated and restricted by a cured and hardened epoxy matrix or other material like the hard layer 16 . Accordingly, the material of the soft layer 14 is a porous material.
- This porous configuration of the soft layer 14 provides a lower flexural modulus than a similar non-porous material, and a flexural modulus lower than its tensile modulus.
- the fiber-reinforced composite material of the hard layer 16 has a tensile modulus greater than its flexural modulus, and the cured and hardened epoxy of the hard layer 16 provides higher rigidity to the hard layer 16 in comparison to the porous soft layer 14 , which does not have the rigid epoxy matrix surrounding the fibers.
- the epoxy matrix also restricts movement of the fibers in the fiber-reinforced composite material of the hard later in response to a flexural load.
- the higher rigidity of the hard layer 16 and the comparative higher tensile modulus of the soft layer 14 prevents the composite assembly 12 from larger deformations.
- the composite assembly When a similar compressive/flexural load is applied in the soft layer side, the composite assembly will have large deformations in the upward flex direction due to the very low rigidity and/or flexural modulus in the soft side to allow greater bending of the composite assembly 12 .
- the only effective rigidity in this condition is the rigidity of the hard layer 16 , as the rigidity of the soft layer 14 is substantially negligible and it collapses or folds on itself as a cloth and does not possess and structure or stability in the compressive/flexural direction or the +/ ⁇ Z axis of the soft sheet layer. Accordingly, movement or deformation of the synthetic fibers within the cured and hardened epoxy of the hard layer 16 are limited so as to prevent the fibers in the hard layer 16 from collapsing or folding on themselves when a flexural force is applied.
- the majority of the woven fabric of the illustrated embodiment is above the neutral bending plane 44 and, with the tensile modulus of the woven fabric being larger than its flexural modulus, bending the composite assembly 12 in a downward direction requires more force than bending the composite assembly 12 in an upward direction, because more of the woven fabric is placed in tension when the assembly 12 is bent in a downward direction.
- the composite assembly 12 has a high resistance to bending in a downward direction while having a comparatively lower resistance to bending in an upward direction.
- the footwear insert 10 expresses similar anisotropic bending properties such that the footwear insert 10 has a high resistance to bending in a dorsal flex direction (i.e., the downward direction) and a low resistance to bending in a plantar flex direction (i.e., the upward direction).
- the composite assembly 12 of the footwear insert 10 provides a higher resistance to bending in the plantar flex direction without significantly limiting bending in a dorsal flex direction, thereby providing stability and comfort to the wearer by preventing undesired bending of the sole assembly 30 without preventing any desired bending.
- the composite assembly 12 of the illustrated embodiment does not provide much resistance to bending in a dorsal flex direction, which may occur during the transition from the flat foot stage of a gait cycle through the toe-off stage during which the wearer's foot naturally bends at the metatarsal joints.
- the increased flexibility helps reduce the forces required by the foot to flex the footwear assembly 22 , thereby reducing fatigue which can help increase stability.
- forces on the sole assembly 30 bend the footwear insert 10 in the opposite, plantar flex direction, such as when a wearer steps on a sharp object or stands on the rung of a ladder, the soft layer 14 is under tension and therefore resists such bending.
- the layered and stacked arrangement of the composite assembly 12 also provides stability during a wearer's gait cycle by controlling the torsional or dorsiflexive motion that helps eliminate the foot's tendency to want to roll inward or outward (pronate and supinate).
- the sole assembly 30 is often subjected to uneven surfaces such as rocks, sidewalk cracks, sticks, ladder rungs, or other sources of unevenness that can create localized forces applied to the bottom of the wearer's foot. These localized forces can apply significant point loads to the wearer's foot.
- the sole assembly 30 with the integrated footwear insert 10 provides a rigid support that laterally displaces the localized forces through a high resistance to bending in the plantar flex direction. Moreover, the footwear insert 10 eliminates the need for the footwear assembly 22 to incorporate a rigid shank (e.g., a shank made from metal, ceramic, plastic shank, etc.) into the sole assembly 30 in order to provide support.
- a rigid shank e.g., a shank made from metal, ceramic, plastic shank, etc.
- FIG. 7A shows a schematic cross-sectional view of the footwear assembly 22 having the footwear insert 10 positioned within the midsole 34 of the sole assembly 30 .
- the footwear insert 10 is embedded within and completely surrounded by the midsole and is sized and shaped to extend fully underfoot.
- the footwear insert 10 may be positioned at different portions of the footwear assembly.
- FIG. 7B depicts an embodiment in which the footwear insert 10 is positioned between the midsole 34 and the upper 28 such that the footwear insert 10 is in immediate contact with an insole board 54
- FIG. 7V depicts an embodiment in which the footwear insert 10 is positioned between the midsole and the outsole 32 .
- the footwear insert may be formed as part of the insole board 54 or the outsole 32 .
- FIG. 8 shows a method 800 of forming a layered composite assembly (e.g., composite assembly 12 ) having anisotropic bending and puncture resistant properties.
- a first layer is provided.
- the first layer is formed from a plurality of sheets of woven mesh fabric stacked together and bonded to each other.
- the sheets of fabric are mechanically joined to each other (e.g., needled or stitched) and a bonding agent (e.g., an adhesive) applied between the layers further binds the layers together.
- the first layer comprises polyester fabric and the woven fabric layer has a thickness in the range of approximately 2.0 mm-5.00 mm thick.
- a second layer is provided.
- the second layer can be a pre-impregnated fiber-reinforced composite layer having fabric, which may be formed from one or more layers of synthetic or other fibers woven together, impregnated with an uncured epoxy.
- the fibers comprise fiberglass and the epoxy comprises a thermoset epoxy.
- the fiberglass fibers are woven together to form one or more sheets of fabric, and the thermoset epoxy is applied to the fiberglass fabric in order to impregnate the fiberglass with the epoxy.
- at least one polymer layer can be provided.
- the polymer layer comprises one or more thin sheets of a block copolymer having polymer chains arranged in a network.
- the polymer layers are arranged on the second layer and the first layer is arranged on the polymer layer.
- only a single polymer layer is provided and applied to the composite layer, such that the first and second layers are only separated by a single sheet of the block copolymer.
- two or more polymer layers are provided such that the first and second layers are separated from each other by two or more sheets of the block copolymer.
- the entire assembly is cured.
- the assembly may be placed in a heat forming tool (e.g., a heat press) that applies pressure and heat to the assembly, causing the first, second, and polymer layers to bind and fixedly attach to each other.
- a heat forming tool e.g., a heat press
- the assembly is heated to approximately 280° F. and a exposed to a pressure in the range of approximately 30-50 psi for approximately 20 minutes.
- the elevated pressure and temperature causes the epoxy to flow around the synthetic fibers of the composite layer and to flow at least partially into the woven fabric layer.
- the polymer layer acts as an interfacing layer that limits the flow of the epoxy into the woven fabric layer and further acts as an adhesive that aids in bonding the fabric layer to the composite layer, thereby co-curing the fabric layer, composite layer, and interfacing layer.
- the assembly is allowed to cool until the epoxy is completely set.
- the hard layer can be cured under appropriate heat and pressure as a first step. The cured hard layer can then be pressed together with the soft and an intermediate polymer layer and heated to approximately 280 F and exposed to a pressure in the range of approximately 25-40 psi for approximately 10-20 minutes.
- the process can be such that the epoxy does not penetrate the fibrous soft material.
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Abstract
Description
- This application relates in general to footwear inserts used in sole assemblies for articles of footwear and, in particular, to footwear inserts having anti-puncture and anisotropic bending properties.
- In general, materials are isotropic or anisotropic. Isotropic materials have identical properties in all directions. Conversely, properties of anisotropic materials are directionally and geometrically dependent.
- Many footwear products incorporate materials that provide a selected degree of stiffness while still allowing for some flexibility for bending during use. Oftentimes, however, desired characteristics within a shoe can be at odds with other desired characteristics. For example, footwear products having sole assemblies that incorporate isotropic materials configured to provide enhanced flexibility and range of motion for the wearer's foot often sacrifice structural stiffness and/or stability. Conversely, the use of isotropic materials to provide enhanced structural stiffness and stability are often at the sacrifice of flexibility.
- Some footwear products also incorporate materials that provide protection and security to a wearer's foot. For example, the sole assemblies of footwear products are often designed to protect the bottom of a wearer's foot from rough and uneven terrain. However, most sole assemblies are typically formed from a relatively soft material (e.g., rubber) that offers little puncture protection from sharp objects, such as nails, screws, wires, spikes, etc. To account for this, footwear products configured to offer improved puncture resistance often include sole assemblies having puncture resistant layers formed from very stiff and rigid materials (e.g., metal, rigid plastic, etc.) or very flexible materials (e.g., fabric such as Kevlar®).
- However, footwear products that incorporate puncture resistant layers formed from very stiff and rigid materials limit the flexibility of the footwear product, thereby reducing the wearer's comfort, while footwear products that incorporate puncture resistant layers formed from very flexible materials offer limited stiffness and stability, resulting in a reduced ability to distribute point loads over larger portions of the sole assembly. Accordingly, there is a need for a footwear insert that can be used as a puncture resistant layer while providing sufficient flexibility to the wearer's foot motion without limiting the stiffness, stability, and load distribution of the footwear product under foot.
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FIG. 1 is an isometric view of a footwear insert formed from a fiber-based composite assembly having anti-puncture and anisotropic properties configured in accordance with embodiments of the present technology. -
FIG. 2 is a side elevation view of a footwear assembly. -
FIG. 3 is an exploded isometric view of the composite assembly forming the insert ofFIG. 1 . -
FIG. 4 is an isometric view of the composite assembly ofFIG. 3 shown in a planar, un-flexed configuration in accordance with embodiments of the present technology. -
FIG. 5 is an enlarged cross-sectional view taken substantially along line 5-5 ofFIG. 4 showing the top and bottom layers of the composite assembly configured in accordance with an embodiment of the present technology. -
FIG. 6 is a schematic side elevation view of the insert ofFIG. 1 shown in an upward deflection configuration (broken lines), neutral configuration (solid lines), and a downward deflection configuration (broken lines). -
FIGS. 7A-C are schematic cross-sectional views of the footwear assembly ofFIG. 2 having the footwear insert ofFIG. 1 in accordance with an embodiment of the present technology. -
FIG. 8 is a schematic flow chart regarding a method of manufacturing the footwear insert ofFIG. 1 in accordance with an embodiment of the present technology. - Various examples of the devices introduced above will now be described in further detail. The following description provides specific details for a thorough understanding and enabling description of these examples. One skilled in the relevant art will understand, however, that the techniques discussed herein may be practiced without many of these details. Likewise, one skilled in the relevant art will also understand that the technology can include many other features not described in detail herein. Additionally, some well-known structures or functions may not be shown or described in detail below so as to avoid unnecessarily obscuring the relevant description.
- The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of some specific examples of the embodiments. Indeed, some terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this section.
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FIG. 1 depicts a footwear insert 10 having puncture-resistant and anisotropic bending properties. Theinsert 10 is shown in a planar, un-flexed configuration. Thefootwear insert 10 is formed from acomposite assembly 12 that comprises asoft layer 14 formed from a woven, fiber reinforced material and ahard layer 16 formed from a fiber reinforced composite material and fixedly and permanently joined with thesoft layer 14. Thefootwear insert 10 has a generally foot-shaped layout that includes aheel portion 18 and anopposing forefoot portion 20, where theheel portion 18 is configured to be positioned beneath a wearer's heel, and theforefoot portion 20 is configured to be positioned beneath a wearer's forefoot when thefootwear insert 10 is incorporated into a footwear assembly 22 (FIG. 2 ). Thefootwear insert 10 has alongitudinal axis 24 extending substantially through both theheel portion 18 and theforefoot portion 20 and alateral axis 26 substantially perpendicular to thelongitudinal axis 24. Thecomposite assembly 12 forming theinsert 10 is a bendable planar assembly which is described herein with reference to the spatial orientation shown inFIG. 1 . Accordingly, thesoft layer 14 is shown inFIG. 1 as a top layer and thehard layer 16 is shown as a bottom layer. It is noted that the terms “top” and “bottom” are used for purposes of convenience to discuss orientation, and it is to be understood that the assembly can be positioned in other spatial orientations, such as an inverted orientation to that shown inFIG. 1 , so that thefirst layer 14 is below thehard layer 16. -
FIG. 2 depicts a footwear assembly 22 (e.g., a shoe) having an upper 28 shaped to receive a wearer's foot and asole assembly 30 that may include thefootwear insert 10. In some embodiments, thefootwear assembly 22 may be a boot, such as a work boot, hiking boot, safety boot, or some other type of boot. In other embodiments, thefootwear assembly 22 may be a shoe, such as a dress shoe, casual/life-style shoe, running shoe, cleated shoe, other athletic shoe, Oxford shoe, or other type of shoe. Additionally, thefootwear assembly 22 can be a sandal or some other type of footwear. The upper 28 is fixedly attached along the bottom margin to asole assembly 30, which includes anoutsole 32 and amidsole 34, where the midsole is fixedly coupled to theoutsole 32 and configured to be positioned between the upper 28 and theoutsole 32. To provide puncture resistance and desirable bending/stiffness properties to thefootwear assembly 22, thefootwear assembly 22 may incorporate the footwear insert 10 (FIG. 1 ) into thesole assembly 30. The incorporatedinsert 10 may be coupled to themidsole 34 and may be sized and shaped such that it extends fully underfoot from aforefoot portion 36, through anarch portion 38, to aheel portion 40 of thefootwear assembly 22. - Conventional footwear sole assemblies traditionally focus on one area of improvement at the sacrifice of another. For instance, a running shoe may increase flexibility and cushioning at the sacrifice of stability and protection. The increased flexibility is commonly achieved through outsole and midsole design that provides segments in the sole in flexing regions of the shoe. While this does increase flexibility, the torsional stiffness can be considerably reduced, and the plantar flex protection can be substantively sacrificed. Another instance is a hiking boot that often sacrifices flexibility for increased protection and stability. The use of rigid materials in the construction of the sole of the hiking boot increases the stiffness so as to distribute loads and reduce transmission of point loads to the wearer's foot, thereby preventing, for example, foot bruising from rocks or roots on a hiking trail.
- The
composite assembly 12 in the form of the footwear insert 10 of the present technology allows for footwear assemblies to have desirable flexibility in one direction substantially corresponding to the natural flex of a wearer's foot through a gate cycle without the sacrifice of the stability and protection. When integrated into thesole assembly 30, thefootwear insert 10 is positioned such that thesoft layer 14 is a dorsal layer configured to be facing upwardly toward a wearer's foot, while thehard layer 16 is a plantar layer configured to belayer 14 facing downwardly away from the foot towards theoutsole 24. As will be discussed in further detail below, the tensile and compressive properties of both the joinedsoft layer 14 and thehard layer 16 cause the footwear insert 10 to have desirable anisotropic bending properties in which the footwear insert 10 has a high resistance to bending in a first direction (e.g., with the toe and/or heel portions flexing downwardly), and a low resistance to bending in an opposing second direction (e.g., with the toe and/or heel flexing upwardly). Because of these desirable bending properties, thefootwear insert 10 provides stability and comfort to the wearer of thefootwear assembly 22 by restricting bending of thesole assembly 30 in a plantar flex direction without adversely affecting bending in a dorsal flex direction. -
FIG. 3 depicts an exploded view of thecomposite assembly 12. Thesoft layer 14 comprises a woven material formed from multiple layers of fabric stacked and coupled together and configured to act as a puncture resistant layer that resists and/or prevents penetration by sharp objects such as nails, screws, and the like. The layers of fabric are each formed from fiber bundles densely woven together into a fine mesh having warp fiber bundles woven with weft fiber bundles, where the warp fiber bundles are substantially parallel to each other and the weft fiber bundles are substantially parallel to each other. The fiber bundles are formed from a non-rigid fibrous material. For example, in a preferred embodiment, the fiber bundles are formed from polyester fibers and the woven material is a polyester material. In other embodiments, the non-rigid fabric is formed from Kevlar, Dyneema (i.e., ultra-high molecular weight polyethylene), or some other flexible woven fabric. The individual layers of fabric are stacked together and mechanically bonded (e.g., stitched, needled, etc.) to each other in a multi-layer arrangement. In this stacked configuration, thesoft layer 14 may have a thickness in the range of between approximately 2.0 mm-5.0 mm. In one embodiment, thesoft layer 14 has a thickness of approximately 4 mm. To promote further bonding and adhesion between the individual layers of fabric, thesoft layer 14 may also include a bonding agent (i.e., a binder or adhesive) applied to the fabric layers so as to further bind the individual layers to each other. Although the illustrated embodiment has asoft layer 14 is a puncture resistant layer made of a woven material formed from multiple layers of fabric stacked and coupled together, thesoft layer 14 in other embodiments can be a puncture resistant layer made of other anti-puncture fabric weaves that can have multiple layers of dense fibers bonded, stitched, or pressed together. - The fibers in the fabric of the illustrated embodiment may be woven such that the warp and weft fiber bundles are oriented at a selected angle relative to each other and/or relative to the
longitudinal axis 24 and thelateral axis 26. In the illustrated embodiment, the warp and weft fiber bundles are woven at approximately a 90-degree orientation relative to each other. In some embodiments, each of the layers of fabric may have a common orientation with respect to the longitudinal andlateral axes longitudinal axis 24. In other embodiments, however, each of the layers of fabric may not be oriented in a common orientation. For example, a first of the layers of fabric may be oriented such that its warp fiber bundles are parallel to thelongitudinal axis 24 while a second of the layers of fabric is oriented such that its warp fiber bundles are oriented at an angle of approximately 30-degrees with respect to thelongitudinal axis 24. - The
hard layer 16 comprises a fiber-reinforced composite material. More specifically, thehard layer 16 comprises a rigid epoxy plate having one or more layers of fibers woven together and impregnated with an epoxy. In a preferred embodiment, the fibers comprise synthetic fibers, such as fiberglass fibers, and the epoxy comprises a cured thermoset epoxy. In other embodiments, the synthetic fibers comprise carbon fibers or some other type of fiber, and the epoxy comprises thermoplastic polyurethanes, thermoplastic elastomers, thermoplastic polyolefins, silicone, acrylates, polyamides, polyurethanes, nitrile and butyl rubbers, and styrenic block copolymers. Other materials and arrangements from which thesoft layer 14 and thehard layer 16 may be formed are described in U.S. patent application Ser. No. 15/220,352, titled JOINED FIBER-REINFORCED COMPOSITE MATERIAL ASSEMBLY WITH TUNABLE ANISOTROPIC PROPERTIES, filed Jul. 26, 2016, which is incorporated by reference herein. - With this stacked and layered arrangement, the
composite assembly 12 acts as a puncture resistant assembly capable of preventing or inhibiting penetration of a foreign objection. For example, the rigid epoxy plate of thehard layer 16 provides impact resistance and maintains overall stiffness of plate when impacted by an object. If the object is able to penetrate through thehard layer 16, however, thesoft layer 14 adds further puncture resistance. The bonded and overlapping fabric layers of thesoft layer 14 are flexible enough to absorb the penetrating objects force and prevent penetration. In addition, when a wearer steps on an object that could puncture a conventional sole assembly, the object applies a point load on a portion of theinsert 10, which causes a portion of theinsert 10 at the load point to flex in the plantar flex direction, which puts the fibers in the soft layer in tension, thereby tightening the fibers together, which further resists and prohibits penetration of the object through the insert to the wearer's foot. As such, the woven fabric merely bends and deforms without breaking and the stacked layers compress into each other without breaking. - Before the
composite assembly 12 is finally assembled and cured, thehard layer 16 includes the woven reinforcing fibers impregnated with uncured epoxy. To form thecomposite assembly 12, thesoft layer 14 is positioned on top of thehard layer 16 and thecomposite assembly 12 is exposed to heat and pressure (e.g., via a heat press) in order to cure the epoxy and bond the twolayers hard layer 16 diffuses partially into thesoft layer 14 and impregnates or otherwise adheres to at least some of the woven fabric of thesoft layer 14. However, if care is not taken, the uncured epoxy may diffuse across the entirety of thesoft layer 14 and impregnate at least most of the woven fabric before curing and hardening. If this happens, the cured epoxy may be too dispersed throughout both of thelayers hard layer 16, resulting in thecomposite assembly 12 being too rigid and thefootwear insert 10 not having the desired bending properties. In another embodiment, thecomposite assembly 12 may be formed by curing the epoxy of thehard layer 16 as an initial process, then in a secondary process position thesoft layer 14 on thehard layer 16 and apply sufficient heat and pressure so as to fixedly bond thesoft layer 14 to thehard layer 16. - As shown in
FIG. 3 , thecomposite assembly 12 of the illustrated embodiment also includes at least oneinterfacing layer 42 positioned between thesoft layer 14 and thehard layer 16. Theinterfacing layer 42 is formed from one or more thin sheets of polymer and is configured to act as an adhesive that bonds thesoft layer 14 to thehard layer 16 while simultaneously preventing the unrestricted flow of uncured epoxy. In a preferred embodiment, the interfacing layers 42 are elastomeric bonding layers formed from sheets of a block copolymer, such as a polyether block amide (e.g., PEBAX 2533), having a thickness in the range of approximately 0.004-0.012 inches (0.1 mm-0.3 mm), and more preferably a thickness of approximately 0.008 inches (0.2 mm) and having polymer chains arranged in a network. During the curing process, the thermal energy and pressure used to cure the epoxy in thehard layer 16 also causes the polymer chains to begin to flow and move around, becoming partially embedded within the soft andhard layers soft layer 14, thehard layer 16, and theinterfacing layer 42 are co-cured together to form thecomposite assembly 12. Once cured, the polymer chains, which now span between the woven fabric and the composite material, permanently bind the two layers together. The cross-linked polymer chains also act as a semipermeable barrier that limits the flow of the epoxy material into thesoft layer 14 from thehard layer 16 during the curing process. While a small portion of the uncured epoxy may be able to flow through theinterfacing layer 42, the majority of the epoxy material is not, thereby ensuring that most of the epoxy remains within thehard layer 16 and that thehard layer 16 has a sufficient stiffness and rigidity, which is greater than that of thesoft layer 14, after the curing process is completed. -
FIG. 4 shows an isometric view of a segment of thecomposite assembly 12 having opposing ends 48 and arranged in a planar and relaxed position (i.e., a neutral orientation), andFIG. 5 shows a cross-sectional view of thecomposite assembly 12 taken along line 5-5 ofFIG. 3 . Theassembly 12 has aneutral bending plane 44 near the bottom of thesoft layer 14 and substantially parallel to theinterfacing layer 42. In a beam or other planar object, the neutral bending plane represents the theoretical plane that separates the portions of the object in tension from the portions in compression when the object is bent. For example, when bending thecomposite assembly 12, portions of thecomposite assembly 12 on one side of theneutral bending plane 44 are in tension, while the portions on the opposing side are in compression. More specifically, bending thecomposite assembly 12 about thelateral axis 24 such that the opposing ends 48 move in a generally upward direction (as shown inFIG. 6 ) causes the portions of thecomposite assembly 12 above theneutral bending plane 44 to be in compression and the portions below theneutral bending plane 44 to be in tension. Conversely, bending thecomposite assembly 12 such that the opposing ends 48 move in a generally downward direction causes the portions of thecomposite assembly 12 above theneutral bending plane 44 to be tension and the portions below theneutral bending plane 44 to be in compression. - Because the different portions of the
composite assembly 12 are placed in either tension or compression when thecomposite assembly 12 is bent, the bending properties (e.g., the resistance to bending in a given direction) of thecomposite assembly 12 are dependent on the tensile and compressive properties of the different portions of thecomposite assembly 12. More specifically, the bending properties of thecomposite assembly 12 are dependent on the tensile and compressive properties of both the woven material of thesoft layer 14 and the fiber-reinforced composite material of thehard layer 16. -
FIG. 6 depicts thecomposite assembly 12 in an upward deflection configuration, a neutral configuration, and a downward deflection configuration. When thecomposite assembly 12 is forced into the upward deflection configuration, all of the material above the neutral bending plane 44 (i.e., a majority of the woven fabric of the soft layer 14) is in compression while all of the material below the neutral bending plane 44 (i.e., the rest of the woven fabric of thesoft layer 14 and all of the hard layer 16) is in tension, and the opposing ends 48 of thecomposite assembly 12 have anupward deflection 50. Conversely, when thecomposite assembly 12 is forced into the downward deflection configuration, the material above theneutral bending plane 44 is in tension while the material below the neutral bending plane is in compression and the opposing ends 48 have adownward deflection 52. - The differences between the tensile and flexural properties of the joined soft and
hard layers composite assembly 12 has anisotropic bending properties. Accordingly, when thecomposite assembly 12 is bent via a force or load (i.e., a flexural load), if the flexural load causes an upward deflection, the extent ofupward deflection 50 will be greater (i.e., the composite assembly will bend more) as compared to the extent ofdownward deflection 52 that will occur in response to the same flexural load applied in the opposite direction. In the illustrated embodiment, thesoft layer 14 has a tensile modulus and a flexural modulus smaller than the tensile modulus and flexural modulus of thehard layer 16. In some embodiments, thesoft layer 14 has a tensile modulus in the range of approximately 0.5 GPa to 15 GPa and the flexural modulus is in the range of approximately 0.01 GPa to 5 GPa. Thehard layer 16, however, has a tensile modulus in the range of approximately 5 GPa to 250 GPa and the flexural modulus is in the range of approximately 1 GPa to 100 GPa. - In the illustrated embodiment, the tensile and flexural modulus of the hard layer are greater than the tensile and flexural modulus of the soft layer. For example, the ratio of the tensile modulus of the
soft layer 14 vs. thehard layer 16 is in the range of approximately 1:1.5 to 1:25. In one embodiment thesoft layer 14 has a tensile modulus of approximately 5 GPa and a thickness in the range of approximately 1.5 mm-5 mm, and the hard layer has a tensile modulus of approximately 30 GPa and a thickness in the range of approximately 0.1 mm-0.25 mm. In another illustrative example, one embodiment of thecomposite assembly 12 has thesoft layer 14 made of woven polyester/Kevlar/Dyneema with a thickness of approximately 4.0 mm, a tensile modulus of approximately 7 GPa. Thehard layer 16 is made of Fiberglass/Epoxy Pre Preg. with a thickness of approximately 0.2 mm, a tensile modulus of approximately 30 GPa. The resultingassembly 12 has a thickness of approximately 4.5 mm. - When the
composite assembly 12 is subjected to a load causing bending in thedownward deflection direction 52, the fabric of thesoft layer 14 is put in tension. As thesoft layer 14 has a higher tensile modulus than its own flexural modulus, it resists the deflection of thecomposite assembly 12 in the downward flex direction. However, when the bending is in the opposite, upward flex direction, the fabric of thesoft layer 14 is under compression. Thesoft layer 14 has very low rigidity and compressive/flexural modulus in comparison to the hard layer, and the fibers of thesoft layer 14 are not encapsulated and restricted by a cured and hardened epoxy matrix or other material like thehard layer 16. Accordingly, the material of thesoft layer 14 is a porous material. This porous configuration of thesoft layer 14 provides a lower flexural modulus than a similar non-porous material, and a flexural modulus lower than its tensile modulus. On the other hand, the fiber-reinforced composite material of thehard layer 16 has a tensile modulus greater than its flexural modulus, and the cured and hardened epoxy of thehard layer 16 provides higher rigidity to thehard layer 16 in comparison to the poroussoft layer 14, which does not have the rigid epoxy matrix surrounding the fibers. The epoxy matrix also restricts movement of the fibers in the fiber-reinforced composite material of the hard later in response to a flexural load. Accordingly, when a compressive, flexural load is applied in the direction of thehard layer 16 to cause bending in the downward flex direction, the higher rigidity of thehard layer 16 and the comparative higher tensile modulus of thesoft layer 14 prevents thecomposite assembly 12 from larger deformations. - When a similar compressive/flexural load is applied in the soft layer side, the composite assembly will have large deformations in the upward flex direction due to the very low rigidity and/or flexural modulus in the soft side to allow greater bending of the
composite assembly 12. The only effective rigidity in this condition is the rigidity of thehard layer 16, as the rigidity of thesoft layer 14 is substantially negligible and it collapses or folds on itself as a cloth and does not possess and structure or stability in the compressive/flexural direction or the +/−Z axis of the soft sheet layer. Accordingly, movement or deformation of the synthetic fibers within the cured and hardened epoxy of thehard layer 16 are limited so as to prevent the fibers in thehard layer 16 from collapsing or folding on themselves when a flexural force is applied. - The majority of the woven fabric of the illustrated embodiment is above the
neutral bending plane 44 and, with the tensile modulus of the woven fabric being larger than its flexural modulus, bending thecomposite assembly 12 in a downward direction requires more force than bending thecomposite assembly 12 in an upward direction, because more of the woven fabric is placed in tension when theassembly 12 is bent in a downward direction. As a result, thecomposite assembly 12 has a high resistance to bending in a downward direction while having a comparatively lower resistance to bending in an upward direction. Accordingly, in embodiments where thefootwear insert 10 incorporates thecomposite assembly 12, thefootwear insert 10 expresses similar anisotropic bending properties such that thefootwear insert 10 has a high resistance to bending in a dorsal flex direction (i.e., the downward direction) and a low resistance to bending in a plantar flex direction (i.e., the upward direction). Further, when thefootwear insert 10 is incorporated into asole assembly 30 for afootwear assembly 22, thecomposite assembly 12 of thefootwear insert 10 provides a higher resistance to bending in the plantar flex direction without significantly limiting bending in a dorsal flex direction, thereby providing stability and comfort to the wearer by preventing undesired bending of thesole assembly 30 without preventing any desired bending. - The
composite assembly 12 of the illustrated embodiment does not provide much resistance to bending in a dorsal flex direction, which may occur during the transition from the flat foot stage of a gait cycle through the toe-off stage during which the wearer's foot naturally bends at the metatarsal joints. The increased flexibility helps reduce the forces required by the foot to flex thefootwear assembly 22, thereby reducing fatigue which can help increase stability. Conversely, when forces on thesole assembly 30 bend thefootwear insert 10 in the opposite, plantar flex direction, such as when a wearer steps on a sharp object or stands on the rung of a ladder, thesoft layer 14 is under tension and therefore resists such bending. The layered and stacked arrangement of thecomposite assembly 12 also provides stability during a wearer's gait cycle by controlling the torsional or dorsiflexive motion that helps eliminate the foot's tendency to want to roll inward or outward (pronate and supinate). Further, during use of thefootwear 10, such as running, walking, hiking, climbing ladders, etc., thesole assembly 30 is often subjected to uneven surfaces such as rocks, sidewalk cracks, sticks, ladder rungs, or other sources of unevenness that can create localized forces applied to the bottom of the wearer's foot. These localized forces can apply significant point loads to the wearer's foot. Thesole assembly 30 with theintegrated footwear insert 10 provides a rigid support that laterally displaces the localized forces through a high resistance to bending in the plantar flex direction. Moreover, thefootwear insert 10 eliminates the need for thefootwear assembly 22 to incorporate a rigid shank (e.g., a shank made from metal, ceramic, plastic shank, etc.) into thesole assembly 30 in order to provide support. -
FIG. 7A shows a schematic cross-sectional view of thefootwear assembly 22 having thefootwear insert 10 positioned within themidsole 34 of thesole assembly 30. In this illustrated embodiment, thefootwear insert 10 is embedded within and completely surrounded by the midsole and is sized and shaped to extend fully underfoot. In other embodiments, however, thefootwear insert 10 may be positioned at different portions of the footwear assembly. For example,FIG. 7B depicts an embodiment in which thefootwear insert 10 is positioned between themidsole 34 and the upper 28 such that thefootwear insert 10 is in immediate contact with aninsole board 54 whileFIG. 7V depicts an embodiment in which thefootwear insert 10 is positioned between the midsole and theoutsole 32. In still other embodiments, the footwear insert may be formed as part of theinsole board 54 or theoutsole 32. -
FIG. 8 shows amethod 800 of forming a layered composite assembly (e.g., composite assembly 12) having anisotropic bending and puncture resistant properties. Atstep 805, a first layer is provided. The first layer is formed from a plurality of sheets of woven mesh fabric stacked together and bonded to each other. The sheets of fabric are mechanically joined to each other (e.g., needled or stitched) and a bonding agent (e.g., an adhesive) applied between the layers further binds the layers together. In a preferred embodiment, the first layer comprises polyester fabric and the woven fabric layer has a thickness in the range of approximately 2.0 mm-5.00 mm thick. - At
step 810, a second layer is provided. The second layer can be a pre-impregnated fiber-reinforced composite layer having fabric, which may be formed from one or more layers of synthetic or other fibers woven together, impregnated with an uncured epoxy. In at least one embodiment, the fibers comprise fiberglass and the epoxy comprises a thermoset epoxy. The fiberglass fibers are woven together to form one or more sheets of fabric, and the thermoset epoxy is applied to the fiberglass fabric in order to impregnate the fiberglass with the epoxy. Atstep 815, at least one polymer layer can be provided. The polymer layer comprises one or more thin sheets of a block copolymer having polymer chains arranged in a network. - At
step 820, the polymer layers are arranged on the second layer and the first layer is arranged on the polymer layer. In some embodiments, only a single polymer layer is provided and applied to the composite layer, such that the first and second layers are only separated by a single sheet of the block copolymer. In other embodiments, two or more polymer layers are provided such that the first and second layers are separated from each other by two or more sheets of the block copolymer. - At
step 825, the entire assembly is cured. The assembly may be placed in a heat forming tool (e.g., a heat press) that applies pressure and heat to the assembly, causing the first, second, and polymer layers to bind and fixedly attach to each other. In a preferred embodiment, the assembly is heated to approximately 280° F. and a exposed to a pressure in the range of approximately 30-50 psi for approximately 20 minutes. The elevated pressure and temperature causes the epoxy to flow around the synthetic fibers of the composite layer and to flow at least partially into the woven fabric layer. However, the polymer layer acts as an interfacing layer that limits the flow of the epoxy into the woven fabric layer and further acts as an adhesive that aids in bonding the fabric layer to the composite layer, thereby co-curing the fabric layer, composite layer, and interfacing layer. Once the epoxy cures and the fiber-reinforced composite layer hardens, the assembly is allowed to cool until the epoxy is completely set. In another embodiment, the hard layer can be cured under appropriate heat and pressure as a first step. The cured hard layer can then be pressed together with the soft and an intermediate polymer layer and heated to approximately 280 F and exposed to a pressure in the range of approximately 25-40 psi for approximately 10-20 minutes. In in some embodiments, the process can be such that the epoxy does not penetrate the fibrous soft material. - While the technology has been particularly shown and described as referenced to the embodiments thereof, those skilled in the art will understand that the foregoing and other changes in form and detail may be made therein without departing from the spirit and scope of the invention. The above description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in some instances, well-known details are not described in order to avoid obscuring the description. Further, various modifications may be made without deviating from the scope of the embodiments.
- Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.
- The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. It will be appreciated that the same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, and any special significance is not to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for some terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any term discussed herein, is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions, will control.
Claims (20)
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EP19728815.2A EP3796803A1 (en) | 2018-05-23 | 2019-05-16 | Footwear insert formed from a composite assembly having anti-puncture and anisotropic properties |
US17/398,958 US20220061456A1 (en) | 2018-05-23 | 2021-08-10 | Footwear insert formed from a composite assembly having anti-puncture and anisotropic properties |
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US11109639B2 (en) | 2021-09-07 |
WO2019226465A1 (en) | 2019-11-28 |
EP3796803A1 (en) | 2021-03-31 |
US20220061456A1 (en) | 2022-03-03 |
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